Product Development Engineer April 9th, 2015 - RTP · PDF fileProduct Development Engineer...
Transcript of Product Development Engineer April 9th, 2015 - RTP · PDF fileProduct Development Engineer...
Jesse Dulek
Product Development Engineer
April 9th, 2015
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Problem Statement• Flame Retardants 101• Chemical Resistance Test Methodology• Development Process• Results• Conclusion / Case Study
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Hospital Acquired Infections– 2,000,000 new cases per year (USA)
– 100,000 deaths per year (USA)– $11 Billion additional cost (USA)
– Global trend
• Costs have been driven back to healthcareproviders
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Added costs have led to an increase incleaner usage and frequency
• Harsh chemicals causing failures in plastichousings
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Increased chemical resistance tohealthcare cleaners vs. traditionalhousing materials
• PC/ABS, PC/PBT, ABS, PC, PC/ASA
• High Impact/Ductility
• Good dimensional stability withshrinkage similar to PC/ABS
• Colorable
• Flame retardant grade forelectronic housings
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Problem Statement• Flame Retardants 101• Chemical Resistance Test Methodology• Development Process• Results• Conclusion / Case Study
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Materials that do not ignite readily or propagate flames under small to moderate fire exposures
• Materials are combustible
• Fire retardants reduce the intensity and spread of fire
• Reduces smoke and toxic by-products of combustion.
Fire Triangle
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Increase Resistance to Ignition
• Reduce Rate of Flame Spread
• Reduce Rate of Heat Release
• Reduce Smoke Emission
•
•
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Flammable
• Polyolefins• Nylons• Polycarbonate• Polyesters• Styrenics• TPE’S
Inherently Flame Resistant
• PolyphenyleneSulfide
• Polyetheretherketone• Polyetherimide• Flouropolymers
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
PTFE
PVC
PVDF
TPI
PSU
PC
Nylon 6/6
PBT
PET
SAN
PMMA
ABS
PP
PE
Cotton
Acetal
0 10 20 30 40 50 60 70 80 90 100
LOI %
Limiting Oxygen Index
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Appliances, Connectors, Housings, etc..• UL 94
– V, 5V, HB
• UL 746– HAI, HWI, CTI
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Classification Criterion
3.0 mm to 13.0 mm thickness– slower than 40 mm/minute or…
– combustion ceases prematurely
< 3.0 mm thickness
– slower than 75 mm/minute or…
– combustion ceases prematurely
** In general most thermoplastics meet this criteria**
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Classification Criteria V-0 V-1 V-2
Number of bar specimens 5 5 5
Maximum flame time per specimen per flame application, sec
10 30 30
Maximum total flame time 5 specimens, 2 ignitions, sec
50 250 250
Specimen drips, ignites cotton No No Yes
Maximum afterglow time per specimen, sec
30 60 60
Burn to holding clamp NO NO NO
**Thickness dependent ratings**
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Flame Retardant – V-0 Non- Flame Retardant – No Rating
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
UL Certification
• RTP Company has 500+ UL Yellowcards– Continuous expansion of UL listed products
• UL Certified Laboratory under Client Test Data Program(CTDP)– Short term properties to UL94
– Long term thermal aging (RTI)
• RTP Company offers custom UL certifications to achievefull commercialization– Quick turnaround
– Compress your Time to Market!
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Problem Statement• Flame Retardants 101• Chemical Resistance Test Methodology• Development Process• Results• Conclusion / Case Study
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Nine day soak test showed no change in physical properties
• Most field failures are seen in areas where stress is applied
• Need a test method that replicates field failures
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Exposure @ 1% Strain
• Patch Method– Saturate patch every 24 hours
– Air dry
• Test tensile properties afterexposure (96 hours)
Test replicated field failures and relative resistance
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Wide variety of chemical cleaners used tohelp avoid the spread of hospital acquiredinfections:– Alcohols
– Aldehydes– Quaternary compounds
– Alkylamine derivatives– Chlorine releasing compounds
– Acidic / Basic solutions– Etc..
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Cleaning Agent Base Chemical Class
Birex Phenol
CaviCide 1 Isopropanol / Ethanol
Cidex Plus Glutaraldehyde
Incides N Propanol
Incidin Plus Glucoprotamin / Ethanol
Incidin Pro Alkylamine / Ethanol
Sani-Cloth Active Quaternary compound
Sani-Cloth Bleach Chlorine releasing compound
Sani-Cloth Plus Isopropanol / Ethanol
Super Sani-Cloth Isopropanol
T-Spray II Alkylamine
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Problem Statement• Flame Retardants 101• Chemical Resistance Test Methodology• Development Process• Results• Conclusion / Case Study
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Healthcare Chemical Resistance Excellent
Izod, Notched (ft-lbs/in) >10
Tensile Strength (psi) >4500
Tensile Elongation (%) >10
Flexural Modulus (psi * 106) 0.2 – 0.5
HDT @ 264 psi (°F) >180
Mold Shrinkage (%) 0.6
UL 94 V-0 / 5VA
Similar Physicals to PC/ABS, Better Cleaner Resistance
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Numerous compositions screened forphysical property and chemical resistance
• Over a dozen polymers tested
• Extensive alloy testing
• Proprietary polyester alloy was proven asbest performer
• Alloy was optimized for physicals, chemicalresistance and flame performance
Introducing RTP 2000 HC series
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Problem Statement• Flame Retardants 101• Chemical Resistance Test Methodology• Development Process• Results• Conclusion / Case Study
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Property RTP 2000 HC PC/ABS RTP 2000 HC FR A FR PC/ABS FR PC/PBT
Tensile Strength (psi) 7000 7500 5750 8000 7250
Tensile Modulus (psi * 106) 0.21 0.32 0.21 0.36 0.32
Tensile Elongation (%) 140% 65% 95% 15% 30%
Flex Strength (psi) 8750 12500 8500 15000 12750
Notched Impact (ft-lbs/in) 16.0 11.0 12.0 12.0 14.0
HDT @ 264 psi ( F)
200 205 190 210 220
Shrinkage (%) 0.5 -0.7 0.5-0.8 0.5-0.7 0.5-0.8 0.7-1.0
Specific Gravity 1.17 1.14 1.27 1.20 1.29
UL 94 HB HB V-0 / 5VA V-0 / 5VA V-0 / 5VA
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Tensile Strength– 75% retention or
greater
• Tensile Elongation– Minimum 10%
tensile elongation
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Cleaner RTP 2000 HC PC/ABS RTP 2000 HC FR A FR PC/ABS FR PC/PBT
T-Spray II
Cidex Plus
Incidin Plus
Birex
Sani-Cloth Active
Sani-Cloth Bleach
CaviCide 1
Super Sani-Cloth
Sani-Cloth Plus
Incides N
Incidin Pro
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Cleaner RTP 2000 HC PC/ABS RTP 2000 HC FR A FR PC/ABS FR PC/PBT
T-Spray II
Cidex Plus
Incidin Plus
Birex
Sani-Cloth Active
Sani-Cloth Bleach
CaviCide 1
Super Sani-Cloth
Sani-Cloth Plus
Incides N
Incidin Pro
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Problem Statement• Flame Retardants 101• Chemical Resistance Test Methodology• Development Process• Results• Conclusion / Case Study
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Market: Medical
Application: Electrical control housing
Problem: Experiencing field failures and all commercially available housing materials were failing chemical testing
Solution: RTP 2000 HC FR A
Benefit: Provided required cleaner resistance, utilizing the existing tooling
Source: iStockphoto LP
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• RTP 2000 HC offers resistance to healthcarecleaners• Available in UL94 V-0/5VA grade (RTP 2000 HC)
• Physical properties well suited for housings
• Dimensional stability
• Similar molding conditions in existing tooling (PC/ABS,PC/PBT, ABS, PC, PC/ASA)
• Fully colorable
• Available for immediate sampling/testing